Mega 150 Inch TV Instructions












Build Your Projector





Welcome,

Thank you for purchasing the 150-Inch TV Kit. Below are the plans to build the projection box that will turn your TV into a giant home theater. If you have not already received your required fresnel lens, it should be arriving in the mail shortly.

I hope you enjoy building the kit. The entire process should take you about 1 hour.

 
















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Instructions #1
    This projector is fairly simple to build and should take around 1 hour to complete. It works great and looks nice when completed.

You can paint the final product any color or you can leave it unpainted. We recommend Silver or Black.
   

 

 

Materials Needed
 

  You will need basic household tools to complete this project
  1. Your existing TV. (A 14" Flat screen TV is shown)
  2. The Fresnel Lens that was mailed to you.
  3. Duct Tape or similar strength tape.
  4. Razor Knife, Scissors, or a sharp kitchen knife. (to cut the cardboard)
  5. Pencil or Pen.
  6. Ruler, or tape measure.
  7. Straight edge, ruler, or square. (To cut on a straight line)
  8. Cardboard. (Thin plywood can be used instead of cardboard)
  9. Black Spray Paint.
   

 

Step #1
 

 

Take a tape measure or ruler and measure the outer length and width of your TV. Not the screen size, but the entire TV.
 

 

Step #2

 

Now you will cut four sides to construct the outer box. First mark out on your cardboard or wood the TV Width of 18". Then mark out one with the TV height of 18"(note your dimensions may be different depending on your TV size). Cut one of each (width and height) and use them as a pattern to cut out the other two. Use the diagrams for a visual aid.
 

 

 

Step #3

Picture #1

Picture #2

Picture #4

  

You can spray paint the inner sides of your cardboard black for a better picture (optional)

  • Now you will take the four pieces from step two to create the outer box (top, bottom, left, and right)

  • Tape each seem with one long piece of duct tape as shown.

    • Picture #1 - Shows a 3D diagram of the constructed and taped outer box. The thick black lines represent were the tape goes.

    • Picture #2 - Lay the tape out flat on the floor in front of the edge of your piece of cardboard.

    • Picture #3 - Lift the cardboard up, set it down covering half of the tape. Make sure the tape sticks all down the entire cardboard.

    • Picture #4 - Shows the seem with two pieces of cardboard. Make sure it's a tight seem by placing the cardboard edges snug against each other. The pull the tape up while you stick it on the second piece of cardboard, thus making a very tight seem.

    • Picture #5 - Shows the completed box where all four seems are taped.

    Tip: Place tape along both the inner and outer edges of the seem to make a stronger box!

 
 

Picture #3

Picture #5

 

Step #4

Picture #1

Picture #2

Picture #3

  

You can spray paint the inner sides of your cardboard black for a better picture (optional)

Now we will make the inner box (focusing box). The inner box will be almost identical to the outer except slightly smaller and will fit inside the outer box snugly.

  • First we will cut four pieces as we did on the outer box. We will also cut a front pieces which will house the lens.

  1. Picture #1 & 2 - Cut two pieces 15" in depth by the width of your TV minus 1/4" (This is so I can fit inside the outer box).

  2. Picture #1 & 2 - Now cut two pieces 15" in depth by the height of your TV minus 1/4".

  3. Picture #1 & 3 - We will also cut a front piece which is the width of your TV by the height of your TV.

  4. Picture #3 - Once you cut the front piece, you will need to cut the center hole which will be covered by the lens. Trace from the corners using a ruler (Red Lines) to locate the center. Then place the provided magnifying lens in the center of the cardboard and trace around it using a pen or pencil (dotted lines). Now trace out a square 1/4" smaller on each side from the dotted line (center solid line). This is so the center cut out is slightly smaller than the lens size. The center cutout will be approx. 6.5" in height by 9.5" in width. Cut out the center of the cardboard using this line.

  5. Picture #4 - Now we will mount the lens on the front cutout. Mount it on the outside of the cardboard (side away from TV) using duct tape. Make sure the smooth side faces away from your TV and the rigid side toward your TV.

  6. Picture #5 - Now we will finish constructing our inner box using all five sides (four side pieces and one front piece). Construct it using duct tape just as you did on the outer box. It will look exactly the same as the outer box except it will have a front piece and be slightly smaller.

 

Picture #4

Picture #5

 

Step #5

 

Now we will place the inner box inside of the outer box and we are about ready to start viewing!

  • This step is pretty straight forward. Simply slide the inner box inside the outer box as shown and place your TV in the back. It should all fit snugly.

  • Now to focus it, you will slide the inner box closer or further from your TV depending on your situation.

  • Unless you have a professional switch the picture yoke (see troubleshooting), you will have to flip your TV upside down. If done carefully, it will not damage your TV. If discoloration occurs, consult the troubleshooting guide.

 

 

Step #6 (optional)

 

   You can now spray paint or cover your projector box to make it more visually appealing. Here I spray painted it using a "Chrome" spray paint, however you can choose to paint it any color you want or for an even nicer look, you can cover it in a fabric of your choosing. This step is optional.
 

 

Focusing Your Projector
   

To focus your projector start within one foot of your wall or screen. Slowly move the entire works away from your wall. Typically 4-10 feet from your wall is used for best viewing. Remember try small adjustments to clearly focus your projector.

  

 

Don't Want to Turn your TV upside down?

Would you rather not turn your TV upside down? Then try this simple method. It's called Tube Yoke Flipping. Simply find a plug with 4 wires (red - blue and yellow - green) and switch the red with the blue/blue with red and yellow with green/green with yellow. Use the picture below for help when asking your local TV repairman to complete this for you.

It takes five minutes and you do not have to have any technical experience to do this! Never opened a TV before? Don't worry! Try this, it's simple and will not damage your TV.

DO NOT OPEN YOUR TV YOURSELF!!! HAVE A TRAINED TV PROFESSIONAL DO THIS FOR YOU!!! TV'S STORE ENERGY EVEN WHEN UNPLUGGED AND YOU CAN BE SEVERELY ELECTROCUTED IF YOU TOUCH THE WRONG THING!!! TAKE YOUR TV TO YOUR LOCAL TV REPAIR SHOP AND THEY CAN COMPLETE THIS FOR YOU FOR ONLY A FEW $$.

AGAIN WE RECOMMEND YOU NOT OPEN YOUR TV YOURSELF! DO NOT TRY IT! IF YOU DO, IT IS AT YOUR OWN RISK!

 

Troubleshooting

To fix the wording or text on your projection from being backward, use the following picture.

Lay the TV on it's back, so the screen faces the ceiling. With the projector attached to your TV, it will project to the ceiling in this position. Now, take a mirror at a 45 degree angle and attach it to the front of your projector box like in the above picture. This will then redirect the projection onto your wall with the text properly displayed.

To Improve Picture Quality:

Good results may be obtained by using a white sheet, a light colored wall, or even a shower curtain. But for best results we recommend you use a Silver Finished Screen made only for projected TV images. This will give you up to 6 - times brighter pictures than any other screen or material. No hot spots. No blurry edges. Can be viewed in partially lighted rooms. HOW TO MAKE YOUR OWN PROJECTOR SCREEN. Simply buy from your local paint store (for about $2.00) a Spray can of either No. 1246 Testors Enamel in Metallic Silver, or No. 1401 Krylon Bright Silver enamel. Spray lightly several coats on wall, ceiling, plywood, wallboard, cardboard, etc. Let dry, and make more applications until a thick and smooth even coat of silver is deposited. This will give you a professional viewing screen that will greatly improve your projected TV image.

 

Blurry edges? Try sandwiching the lens in between two panels of flat glass. This will insure the lens is completely flat and thus project a better picture!

 

Color Problems When you Turn your TV Upside Down?

When you flip your TV upside down, do you get some discoloration? Try this method to fix any discoloration...

  1. Turn your TV upside down.

  2. Turn it on and verify the colors are wrong.

  3. Turn your TV off, but leave it plugged in.

  4. Leave your TV off but still plugged in for AT LEAST 30 minutes.

  5. Turn your TV back on. The colors should be fixed.

(MAKE SURE YOU LEAVE YOUR TV PLUGGED IN THE WHOLE TIME WHILE DOING THIS.)

 

Congratulations - You’re Done!

If you have additional questions about building your kit, please feel free to e-mail the person who sold it to you.

I hope you enjoyed building your kit and wish you the best with your new home theater!

 

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